EP1814720B1 - Procedes et dispositif de demoulage de lentilles ophtalmiques - Google Patents

Procedes et dispositif de demoulage de lentilles ophtalmiques Download PDF

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Publication number
EP1814720B1
EP1814720B1 EP05815086A EP05815086A EP1814720B1 EP 1814720 B1 EP1814720 B1 EP 1814720B1 EP 05815086 A EP05815086 A EP 05815086A EP 05815086 A EP05815086 A EP 05815086A EP 1814720 B1 EP1814720 B1 EP 1814720B1
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EP
European Patent Office
Prior art keywords
lens
mold assembly
cooling
assembly
cooled
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP05815086A
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German (de)
English (en)
Other versions
EP1814720A2 (fr
Inventor
Robert John Watterson, Jr.
Richard W. Leavitt
Mark A. Litwin
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Johnson and Johnson Vision Care Inc
Original Assignee
Johnson and Johnson Vision Care Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Johnson and Johnson Vision Care Inc filed Critical Johnson and Johnson Vision Care Inc
Publication of EP1814720A2 publication Critical patent/EP1814720A2/fr
Application granted granted Critical
Publication of EP1814720B1 publication Critical patent/EP1814720B1/fr
Active legal-status Critical Current
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00038—Production of contact lenses
    • B29D11/00125—Auxiliary operations, e.g. removing oxygen from the mould, conveying moulds from a storage to the production line in an inert atmosphere
    • B29D11/00192—Demoulding, e.g. separating lenses from mould halves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0003—Discharging moulded articles from the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/22—Component parts, details or accessories; Auxiliary operations
    • B29C39/36—Removing moulded articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00432—Auxiliary operations, e.g. machines for filling the moulds
    • G—PHYSICS
    • G02—OPTICS
    • G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
    • G02C7/00—Optical parts
    • G02C7/02—Lenses; Lens systems ; Methods of designing lenses
    • G02C7/04—Contact lenses for the eyes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • B29L2011/0016—Lenses
    • B29L2011/0041—Contact lenses

Definitions

  • This invention related to methods for demolding ophthalmic lenses.
  • the pliable lenses can be damaged by the force used to remove either or both the male or female halves of the lens mold.
  • Others have attempted to solve this problem by a variety of methods. In one such attempt, the male mold half is heated prior to the demolding step and subsequently removed. See , U.S. Pat. No. 6,663,801 . Even though this method is effective, it does not work with all types of soft contact lenses and it would be advantageous to have additional methods of demolding contact lens molds. This need is met by the following invention.
  • This invention includes a method of demolding a soft contact lens comprising cooling the lens mold assembly and heating the lens mold assembly prior to demolding the soft contact lens, wherein the soft contact lens is a silicone hydrogel, according to claim 1.
  • ophthalmic lens refers to a device that resides in or on the eye. These devices can provide optical correction or may be cosmetic.
  • Soft contact lens formulations are disclosed in US Patent No. 5,710,302 , WO 9421698 , EP 406161 , JP 2000016905 , U.S. Pat. No. 5,998,498 , U.S. Patent No. 6,087,415 , U.S. Pat. No. 5,760,100 , U.S. Pat. No.5,776, 999 , U.S. Pat. No. 5,789,461 , U.S. Pat. No. 5,849,811 , U.S. Pat. No.
  • the particularly preferred lenses of the inventions made from etafilcon A, genfilcon A, galifilcon A, senofilcon A, lenefilcon A, Iotrfilcon A, Iotrifilcon B, balifilcon A, or polymacon. More particularly preferred lenses of the invention made from genfilcon A, galifilcon A, senofilcon A, lenefilcon A, lotrfilcon A, lotrifilcon B, or balifilcon A,.
  • the most preferred lenses include but are not limited to galifilcon A, senofilcon A, and lenses disclosed in U.S. Pat. No. 6,822,016 .
  • “Lens mold assembly” refers a combination of three components, a male mold, a female mold and a cured lens.
  • the male and female molds may be made from a variety of components such as plastics, metals and glass.
  • the preferred molds are plastics. Examples of such plastics include but are not limited to materials disclosed in U.S. Pat. App. 2004-0075039 A1 .
  • Other mold materials are polymers copolymers, homopolymers and block co-polymers of polystyrene, polypropylene, and polyethylene. Examples of plastic molds are disclosed in the following documents, U.S. Pat Nos. 5,094,609 ; 4,565,348 ; and 4,640, 489 .
  • the male and female mold need not be of the same material.
  • a lens mold assembly having a female mold made of a polypropylene and a male mold made of an alicyclic co-polymer of norbonene may be used.
  • the particularly preferred mold material is an alicyclic co-polymer that contains two different alicyclic monomers and is sold by Zeon Chemicals L.P. under the tradename ZEONOR.
  • ZEONOR Zeon Chemicals L.P.
  • the particularly preferred ZEONOR is ZEONOR 1060R, which according to the manufacturer, ZEON Chemicals L.P.
  • MFR melt flow rate
  • cooling refers to any method of reducing the temperature of the lens mold assembly.
  • the lens mold assembly In the process of curing ophthalmic lenses, the lens mold assembly is heated and subjected to radiation. When this assembly leaves the curing portion of the manufacturing process, the temperature of the assembly is about 50 to about 70°C.
  • This heated lens mold assembly is cooled by one of the methods described below and prior to demolding. It is preferred that the lens mold assembly be cooled to a temperature of about 0°C to about less than 45°C, more preferably about 3 °C to less than about 30°C.
  • One method of cooling the lens mold assembly is to blow compressed air on the lens mold assembly where the temperature of the forced air is about -40°C to about +5°C and the rate of air flow (standard cubic feet per minutes, "SCFM") is about 5 SCFM to about 100 SCFM, preferably about 18 SCFM.
  • the forced air can be directed at the entire lens mold assembly or a particular part of the lens mold assembly.
  • forced air may be directed at either the female mold's non-molding surface (convex surface) or the male mold's non-molding surface (concave surface).
  • the forced air is directed to the concave surface of the male mold.
  • Another method of cooling the lens mold assembly is to blow solid CO 2 particles on the lens assembly.
  • the temperature of those particles is about -60 to about -O°C, preferably about -50°C.
  • Those particles are discharged at a rate of about 0.5 SCFM to about 10 SCFM, preferably about 3 SCFM.
  • Solid CO2 may be directed to the entire lens mold assembly or a portion thereof. It is preferred that the solid CO 2 be directed to the non-molding surface of the male mold.
  • Other methods of cooling the lens mold assembly include but are not limited to allowing the assembly to come to room temperature, placing the assembly in a refrigerated chamber, placing the assembly in the proximity of a thermoelectric chiller or a cool liquid, such as ice water. The preferred methods of cooling are using forced cold air or solid CO 2 particles.
  • heating refers to any method of elevating the temperature of the lens mold assembly including but not limited to applying steam, forced hot air, or heat to the lens mold assembly. Examples of such heating methods may be found in the following references EP 775,571 ; EP 686,487 ; U.S. Pat. App. No. 2002/0145,211 ; U.S. Pat Nos. 5,820,895 ; 6,171,529 ; 5,850,107 ; 5,294,379 ; 5,935,492 ; and 5,770,119 . Either the entire lens mold assembly may be heated or a portion thereof.
  • One method of heating the lens mold assembly uses a silicon carbide infra-red emitter and is disclosed in U.S. Pat. No. 6,663,801 . If this heating method is used the heat is applied to the non-molding surface of either the male or the female mold part. It is particularly preferred that heat is applied to the non-molding surface of the male mold.
  • the male mold of the lens mold assembly may be demolded using shims, pry fingers, or other types of mechanical leverage. See , EP 775,571 ; EP 686,487 ; U.S. Pat. App. No. 2002/0145,211 ; U.S. Pat Nos. 5,820,895 ; 6,171,529 ; 5,850,107 ; 5,294,379 ; 5,935,492 ; and 5,770,119 for experimental details.
  • the male molds may be removed by applying a vacuum to the male molds to demold it. It is preferred that a combination of mechanical means and vacuum is used to demold the male mold member.
  • the methods of this invention have many advantages. Most ophthalmic lenses are made.in a manufacturing environment where speed from processing station to processing station is important. Using the cooling and subsequent heating steps of this invention significantly shorten the period of time between the exit of the lens from the curing area and demolding of the lens. It is preferred that the period of time between removing the lens from the curing area and demolding the lens be less than about 20 seconds, preferably less, than about 15, seconds, more preferably less than about 10 seconds.
  • a further advantage of the invention is that by cooling and subsequently heating either the male or the female mold member, one can remove the heated mold and leave the lens sitting in or adhered to the non-heated mold part. This is an advantage because some manufacturing processes require that subsequent processing steps (hydration, excess monomer removal, and the like) are conducted in either the male or female lens mold.
  • Another advantage of this invention is that fewer of the ophthalmic lenses are damaged by the demolding process. This is demonstrated by the reduced number of demolded lenses with mold related defects such as tears, chips, surface marks, surface tears.
  • mold related defects such as tears, chips, surface marks, surface tears.
  • the invention includes an apparatus suitable for cooling and heating a lens mold assembly prior to demolding the assembly comprising a cooling component and a heating component, wherein the cooling component produces solid CO 2 particles, according to claim 17.
  • the terms cooling, heating lens mold assembly, and demolding all have their aforementioned meanings and preferred ranges.
  • the preferred cooling components are solid CO 2 blowers.
  • the preferred heating components are infra-red heaters.
  • the uncured monomer used to prepare galifilcon A was placed between a male and a female mold halves made of Zeonor and cured as describe in U.S. Pat App. No. 60/318 , 536 and U.S. Serial No. 10/236,538 .
  • the temperature of the cured lens mold assembly was approximately 65°C.
  • the concave surface of the male molding member was heated with a silicon infra-red heater and demolded as described in U.S. Pat. No. 6,663,801 .
  • Some lens mold assemblies were cooled by blowing cold air (-40°C, 18 SCFM) on the concave surface of the male mold for 2, 3, 4, or 8 seconds.
  • the cooled lens assembly was heated with a silicon infra-red heater and demolded as described in U.S. Pat. No. 6,663,801 .
  • the demolded lenses were evaluated to determine if they remained with the female mold member.
  • the results are presented in Figure 1 . This figure shows that without cooling prior to demold less than 5% of the lenses remain with the female mold member.
  • This example evaluates defects in the cured lenses due to demolding.
  • the uncured monomer used to prepare galifilcon A was placed between a male and a female mold halves made of Zeonor and cured as describe in U.S. Pat App. No. 60/318, 536 , and U.S. Serial No. 10/236,538 .
  • the temperature of the cured lens mold assembly was approximately 65°C.
  • Lens mold assemblies were cooled by blowing solid CO 2 (-50°C, 3 SCFM) on the concave surface of the male mold for about 2 seconds.
  • the cooled lens assembly was heated with a silicon infra-red heater and demolded as described in U.S. Pat. No. 6,663,801 . All of the demolded lenses remained with the female mold member.

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  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Ophthalmology & Optometry (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • General Health & Medical Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Eyeglasses (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Cleaning In General (AREA)

Abstract

L'invention concerne des procédés et des appareils conçus pour démouler des lentilles ophtalmiques.

Claims (20)

  1. Procédé pour démouler une lentille de contact souple, comprenant le refroidissement de l'assemblage de moule de lentille et le chauffage de l'assemblage de moule de lentille avant démoulage de la lentille de contact souple, caractérisé en ce que la lentille de contact souple est un hydrogel de silicone.
  2. Procédé selon la revendication 1, dans lequel la lentille de contact souple comprend de l'étafilcon A, du genfilcon A, du galyfilcon A, du sénofilcon A, du lénéfilcon A, du lotrafilcon A, du lotrafilcon B, du balafilcon A ou du polymacon.
  3. Procédé selon la revendication 1, dans lequel la lentille de contact souple comprend du galyfilcon A ou du sénofilcon A.
  4. Procédé selon la revendication 1, dans lequel l'assemblage de moule de lentille est refroidi à une température d'environ 0°C à environ 40°C.
  5. Procédé selon la revendication 1, dans lequel l'assemblage de moule de lentille est refroidi par de l'air froid forcé.
  6. Procédé selon la revendication 1, dans lequel l'assemblage de moule de lentille est refroidi par des particules solides de CO2.
  7. Procédé selon la revendication 1, dans lequel la partie de moule mâle de l'assemblage de moule de lentille est refroidi par de l'air froid forcé ou des particules solides de CO2.
  8. Procédé selon la revendication 7, dans lequel l'assemblage de moule de lentille est refroidi à une température d'environ -25°C à environ +40°C.
  9. Procédé selon la revendication 6, dans lequel l'assemblage de moule de lentille est refroidi à une température d'environ -25°C à environ +10°C.
  10. Procédé selon la revendication 7, dans lequel l'assemblage de moule mâle est refroidi.
  11. Procédé selon la revendication 9, dans lequel l'assemblage de moule mâle est chauffé.
  12. Procédé selon la revendication 11, dans lequel la température de l'assemblage de moule de lentille est d'environ 20°C à environ 40°C.
  13. Procédé selon la revendication 11, dans lequel la température de l'assemblage de moule de lentille est d'environ 25°C à environ 30°C.
  14. Procédé selon la revendication 13, dans lequel les étapes de refroidissement ont lieu en moins de 10 secondes.
  15. Procédé selon la revendication 13, dans lequel les étapes de refroidissement et de chauffage ont lieu en environ 9 à environ 20 secondes.
  16. Procédé selon la revendication 13, dans lequel les étapes de refroidissement et de chauffage ont lieu en moins d'environ 12 secondes.
  17. Dispositif adapté pour refroidir et chauffer un assemblage de moule de lentille avant démoulage, l'assemblage comprenant un composant refroidissant et un composant chauffant, caractérisé en ce que le composant refroidissant produit des particules solides de CO2.
  18. Dispositif selon la revendication 17, dans lequel le composant refroidissant refroidit l'assemblage de lentille à une température d'environ -25°C à environ +10°C.
  19. Dispositif selon la revendication 17, dans lequel le composant chauffant chauffe l'assemblage de lentille à une température d'environ 20°C à environ 40°C.
  20. Dispositif selon la revendication 17, dans lequel le refroidissement et le chauffage ont lieu en environ 9 à environ 20 secondes.
EP05815086A 2004-11-05 2005-11-02 Procedes et dispositif de demoulage de lentilles ophtalmiques Active EP1814720B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/982,232 US20060097415A1 (en) 2004-11-05 2004-11-05 Methods of demolding ophthalmic lenses
PCT/US2005/039450 WO2006052533A2 (fr) 2004-11-05 2005-11-02 Procedes de demoulage de lentilles ophtalmiques

Publications (2)

Publication Number Publication Date
EP1814720A2 EP1814720A2 (fr) 2007-08-08
EP1814720B1 true EP1814720B1 (fr) 2010-01-20

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EP05815086A Active EP1814720B1 (fr) 2004-11-05 2005-11-02 Procedes et dispositif de demoulage de lentilles ophtalmiques

Country Status (13)

Country Link
US (1) US20060097415A1 (fr)
EP (1) EP1814720B1 (fr)
JP (1) JP4855411B2 (fr)
KR (1) KR20070085811A (fr)
CN (1) CN101052511B (fr)
AR (1) AR052125A1 (fr)
AU (1) AU2005305131B2 (fr)
BR (1) BRPI0517665B1 (fr)
CA (1) CA2586407C (fr)
DE (1) DE602005019085D1 (fr)
HK (2) HK1105920A1 (fr)
TW (1) TWI382927B (fr)
WO (1) WO2006052533A2 (fr)

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7799249B2 (en) * 2005-08-09 2010-09-21 Coopervision International Holding Company, Lp Systems and methods for producing silicone hydrogel contact lenses
MX2008011877A (es) * 2006-03-20 2008-11-28 Coopervision Int Holding Co Lp Auxiliares para desprendimiento de moldes de hidrogeles de silicona y metodos relacionados.
US7811483B2 (en) * 2006-06-01 2010-10-12 Coopervision International Holding Company, Lp Delensing of ophthalmic lenses using gas
WO2007143418A2 (fr) * 2006-06-01 2007-12-13 Coopervision International Holding Company, Lp Démoulage de lentilles ophtalmiques par l'utilisation de gaz
US8313675B2 (en) * 2009-08-31 2012-11-20 Coopervision International Holding Company, Lp Demolding of ophthalmic lenses during the manufacture thereof
CN105345964A (zh) * 2015-11-10 2016-02-24 丹阳佰易视光学眼镜有限公司 一种树脂镜片自动脱模设备及方法
CN109334061A (zh) * 2018-08-16 2019-02-15 江苏硕延光学眼镜有限公司 一种具有高耐冲击和高耐热性光学树脂组合物的制备工艺

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US5294379A (en) * 1992-09-18 1994-03-15 Johnson & Johnson Vision Products, Inc. Laser assisted demolding of ophthalmic lenses
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AU706496B2 (en) * 1995-11-21 1999-06-17 Johnson & Johnson Vision Products, Inc. Infra-red heat source for demolding contact lenses
US5820895A (en) * 1996-06-04 1998-10-13 Johnson & Johnson Vision Products, Inc. Conductive probe for heating contact lens mold assemblies during demolding
EP1009581A4 (fr) * 1997-02-20 2004-07-28 Technology Resource Int Corp Procede et appareil d'assemblage de dispositif de fabrication de lentille
FR2790993B1 (fr) * 1999-03-17 2001-06-15 Essilor Int Procede de demoulage d'un article en materiau polymere transparent et son utilisation pour la fabrication d'un article en materiau polymere transparent tel qu'une lentille ophtalmique
ATE300418T1 (de) * 1999-10-27 2005-08-15 Novartis Pharma Gmbh Entformung von kontakt-linsen
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US6663801B2 (en) * 2001-04-06 2003-12-16 Johnson & Johnson Vision Care, Inc. Silicon carbide IR-emitter heating device and method for demolding lenses
US20030164563A1 (en) * 2002-03-04 2003-09-04 Olin Calvin Use of microwave energy to disassemble, release, and hydrate contact lenses

Also Published As

Publication number Publication date
BRPI0517665B1 (pt) 2016-09-06
BRPI0517665A (pt) 2008-10-14
AR052125A1 (es) 2007-03-07
JP4855411B2 (ja) 2012-01-18
US20060097415A1 (en) 2006-05-11
DE602005019085D1 (de) 2010-03-11
AU2005305131B2 (en) 2011-09-08
EP1814720A2 (fr) 2007-08-08
CN101052511B (zh) 2011-10-19
CA2586407A1 (fr) 2006-05-18
TW200633848A (en) 2006-10-01
HK1113557A1 (en) 2008-10-10
CN101052511A (zh) 2007-10-10
HK1105920A1 (en) 2008-02-29
TWI382927B (zh) 2013-01-21
JP2008519316A (ja) 2008-06-05
CA2586407C (fr) 2014-04-01
WO2006052533A3 (fr) 2006-06-29
KR20070085811A (ko) 2007-08-27
AU2005305131A1 (en) 2006-05-18
WO2006052533A2 (fr) 2006-05-18

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